Process of producing high-grade steel from low-grade material.



UNITED STATES PATENT OFFICE.

WILLIAM R. PALMER, OF BRIDGEPORT, CONNECTICUT, ASSIGXOR OF ONE-HALF TO FRANK A. WILMQT, OF BRIDGEPORT, CONNECTICUT. I

W58 PRODUCING HIGH-GRADE STEEL FROM LOW-GRADE MATERIAL.

Specification of Letters Patent.

Patented June 1 5, 1909.

Application filed March 5, 1909. Serial Nd. 481,425.

To 41E whom it may concern:

known that 1, WILLIAM R. PALMER, a'citizen of the United States, residing at Bridgeport, in the county of Fairfield and 5 State of Connecticut, haye invented certain newand useful Improvements'in Processes ofPreducing High-Grade Steel from Low- Grade Material; and i. do hereby declare the following to be a full, clear, and exact de' one-fourth per cent. in silicon, Whereas foundry pig iron from which castings and cast on orings are produced exceeds both basic and off-basic pig in silicon, phosphorus and sulfur and its scrap makes too acid a bath to permit of any considerable portion of the J scrap\being used. in basic open-hearth. furnames because of the acid bath attacking the basic liningv of the furnace at steehmaking temperatures, the silicon being particularly '30s1a'cti e in attacking the basic lining.

- The. ordinary process of making basic openheaiith steel consists in charging a furnace pig iron and scrap together with the necessary fluxand then melting and working charge toith'e-desired chemical coni-posi-.

tion temperature. The flux, ordinarily limesto 'e, forms a, slag which absorbs and retains ,the impuritiesy silicon, sulfur and phosph rus, to agreate-rz-or less extent de- 4 pendent on the basic qualities of the slag so formed,l thereby. purifying the metal. Simultandously, however, with the oxidation of the impurities the carbon also is partially oxidized and the furnace must be charged 5 with sufficient carbon in some form to cover this loss by oxidation and to insure sullic'ient carbon remainingin the bath after the metallic charge is melted. This required carbon is generally contained in the pig iron,

5 and the furnace must therefore be charged with sufficient pig iron to im art the necessary amount of carbon to t e bath. As pig iron is the most expensive portion of the charge, the addition of the necessary amount steel.

borings in this process.

of pig iron greatly increases the cost of the steel.

My present invention enables me to greatly reduce the cost of production of high grade This I accomplish by using in lieu of pig iron, materials that are commercially worth one-half, more or less, the cost of pig ron, as for example cast iron borings, large pieces of castings, cast scrap and other low grade material which cannot be used in any appreciable quantity in the ordinary open hearth process on account of the high percentage of impurities they contain.

Cast iron borings are of somewhat similar composition to pig iron, but cannot be used in the ordinary process of making basic 0 pen hearth steel for the reason that the percentage of silicon in cast iron borings is so much higher than in basic pig iron as to cause the destruction or scorification of the furnace hearth, and the neutralizing and destroying of the basic effect of the limestone and interfering with the removal of the other impurities. The percentage of sulfur is also much higher in cast iron borings than in pig iron owing to the absorption of sulfur from the fuels in former Incl-tings. Sulfur, in fact, is the most difficult impurity to remove or oxidize from the bath, and if not removed or oxidized greatly decreases the quality and value of the steel. Still another reason Why cast iron borings cannot be used in the ordinary open hearth process of making steel is their physical condition, they being finely granular or powdered, which renders them unfit for use in appreciable quantity in the ordinary open hearth process as this condition interferes with'the melting, the material lying in such close mass that the heat will not penetrate and long delayed melting results from the use of any appreciable quantity of The same is true both as regards the physical and chemical composition of large castings or chunks or large pieces of cast iron. Vi'ith this description of the lOW grade niaterials which I may use in carrying out my novel process and the physical and chemical characteristics thereof, itwill be sufficient to refer to them generically as low grade material. I

In carrying outniy invention I use'two or more open-hearth furnaces, the first of which. I call the primary furnace and the other or others secondary or finishing furnaces, for the reason that a single primary furnace will keep from two to four secondary furnaces running, depending of course upon the size of the furnaces. The primary furnace I run at what is relatively a low temperature in steel making, for example at a temperature onethousand degrees Fahrenheit, more or less, below the ordinary temperature of steel making. The secondary furnace or furnaces are run at ordinary steel-makingtemperatures.

The running of the primary furnace at a relatively low temperature prevents any apreciable attack of the silicon on the basic ining of the furnace and also partially eliminates the silicon, phosphorus and sulfur. From this primary furnace I tap for use in the secondary furnace a molten metal representing in analysis a semi-pig or semi-steel.

it being refined as to silicon, phosphorus and sulfur to about one-half of the percentage of these elements contained'in basic pig iron, the further refinement at steel-making temperatures being accomplished in the secondary furnace. The primary furnace may be of the tilting type and the secondary furnace of furnaces of the stationary type. In starting, the primary furnace is charged with pig iron or with large chunks or pieces of cast iron to form a liquid bath of iron to which is added sufficient flux to cover the metal and to partially oxidize the impurities at the same time preventing oxidation of the metal.-

It should be noted that this is done only in starting the primary furnace, as thereafter sufficient metal is left in the primary furnace to form the bath.

After the bath is so formed the low grade material as already defined, either as me tallic iron or iron oxid, is added in such quantities and as rapidlyas the melting will permit together with. the required amount of flux in the shape 6f limestone or other materials cold or in the shape of fluid slag from'th'e finishing furnace or furnaces, as will be more fully explained.

The secondary or finishing furnace is partially charged with any low grade material as scrap and a sullicientquantity of flux and when the heated metal is in semi-molten condition it is ready for the molten metal from the primary furnace.

In transferring the molten metal from the primary furnace to a secoinlary furnace, if the secondary furnace is at a low enough level, the molten metal may 'be poured from the primary furnace into a trough at sufficient incline to permit it to flow into the secondary furnace. This arrangement is not common, however, with furnaces already in use. Ordinarily in transferring the metal I pour it from the primary furnace into a ladle which is handled by a crane. Suppose .il)\\' that the partial charge in the secondary furnace has been brought to a suitable condition, and the charge in the primary furnace is ready for pouring. The quantity of metal that it is desired to transfer is poured from the primary furnace into the ladle which is moved to the secondary furnace and the metal delivered thereto from the ladle. ll will be noted that a sufficient quantity of the molten metal, one-half more or less of thecharge, is left in the primary furnace. This molten metal in the primarv furnace forms a bath which facilitates and hastens the melting of the next charge of low grade material which may then be placed in the primary furnace. Xo slag from the primary furnace is allowed to enter the secondary furnace, but this slag having lost its efficiency is removed. When'the charge in the secondary furnace has reached the proper conditionit is drawn off in the usual manner. The efficiency of the slag from the secondary furnace. however.-has been only )artially impaired by the operation of said furnace. After the tapping of the heat of steel from the secondary furnace the slag from said furnace may or may not be run into the ladle and transferred to the primary furnace to assist in the working of the charge therein. This charge of molten slag from the sec ndary furnace. assists to a certain extent in working the charge in the primary furnace and also acts to partially remove and retain the impurities from the charge in the primary furnace. -\s

this slag is charged in a molten condition.

there is no cooling effect produced by it auil no retarding of the work of the primary furnace. The charging of the slag from the secondary furnace into the primary furnace has this further beneficial effect of immediately protecting the metal from oxidation and protecting the furnace bottom from scol'illt'zltion. As it is already formed the loss of car bon resulting from the formation of new slag is avoided.

As soon as the secondary furnace has been drawn off it may be immediately partially charged again with scra or other low grade material; even cast iron )t)llll $IS may be used in moderate quantities. The essential feature of the invention. however. is that by .partially refining the charge in the primary furnace. then transferring a portion-of the charge to the secoinlary furnace for the complction of the refining operation and leaving suflicient molten metal in the n'imary furnace to form a molten bath for the next charge of low grade material, .l avoid the. necessity for the use of pig iron or any highgrade material to furnish the necessary amount of carbon and produce a high grade of steel from a low grade of lllutcliul. The operation at the secondary furnace is greatly hastened by the addition of the charge of molten mclal from the primary furnace. .\s the charge in the secoinlury furnace is already in a suitablc condition. the more or Ill.)

less violent reaction produced by the charge of. molten metal from the primary furnace will remove the impurities Very rapidly. I find in practice that furnaces operated by this process produce as much, or more, steel from a charge of low grade material as from an ordinary pig iron and scrapucharge, andthat the ste so produced is lly equal in physical qualities and chemical composition to steel produced from a pig iron and scrap charge.

- Having thus described my invention, I claim 1. In the manufacture of open-hearth steel, the process which consists in charging a primary furnace with low grade material of the character described, operating said furnace at a temperature below ordinary steel-making temperatures, partially charging a secondary furnace with low grade material, operating said furnace at ordinary steel-making temperatures andjtransferring a portion of the charge of the primary furnace to the secondary furnace for the completion of the refining operation leaving a portion of the charge in the primary furnace to form a bath to receive the next charge of low grade material? 2. In the manufacture of open-hearth steel, the process which consists in charging a primary furnace with low grade material of the character described, operating said furnace at a temperature below ordinary steel, the. process which consists in charging a primary furnace with-low grade material of the character described, 0 erating said furnace at a temperature be ow ordinary steel-making temperatures, partially charging asecondary: furnace with low grade material and flux, operating said furnace at ordinary steel-making temperatures, transferring a portion of the charge from the primary furnace to the secondary furnace for the completion of the refining operation, leaving a portion of the charge in the primary furnace to form a molten bath, re-

charging the primary furnace with low grade material and charging the primary furnace with slag from the secondary furnace.

In testimony whereof I aflix my signature in presence of two witnesses. WILLIAM R. PALMER.

lVitnesses:

A. W. Woos'rER, S. W. ATHERTON. 

